[1] Equipment and facilities
1. Reactors and reactors
1) Abnormal noise of reducer
2) There is too much oil on the reducer or rack.
3) Hot melt deformation of plastic fan blades of speed reducer
4) The mechanical seal and reducer are short of oil.
5) gasket leakage
6) Anti-static grounding wire is damaged and not installed
7) The safety valve has not been inspected, leaked or set up an account.
8) The thermometer is not inspected and damaged.
9) The pressure gauge is overdue for annual inspection, damaged or blocked by materials.
10) Double sets of temperature and pressure display, recording and alarm are not used in key reactors.
11) The bursting disc has not been replaced, leaked, and an account has not been established.
12) The lower valve of bursting disc is not opened.
13) There is no bursting disc in the reaction kettle with explosion danger.
14) Abnormal pressure increase or material flushing due to high temperature and interruption of stirring.
15) When discharging, the bottom valve is easily blocked.
16) Stainless steel or carbon steel kettle has acid corrosion.
17) overload operation when the loading exceeds the specified limit.
18) The damaged enamel in the enamel kettle is still used in corrosive, flammable and explosive places.
19) The inner container of the reaction kettle is damaged by erosion at the steam inlet of the jacket.
20) The pressure vessel has exceeded its service life and its manufacturing quality is poor, and it still leaks after repeated repairs.
21) Pressure vessel has no nameplate.
22) The absence number is marked or unclear.
23) Failure to effectively isolate the reactor with explosion sensitivity.
24) No safety checklist has been made for important equipment.
25) Important equipment is short of spare parts or standby machines.
2, storage tank, tank farm, tank car
1) The level gauge is fuzzy or damaged or blocked.
2) Electrostatic grounding wire is loose or not connected.
3) Leakage at flange gasket
4) High storage tanks such as small platforms are not effectively fixed.
5) The liquid level of safety liquid seal does not meet the requirements.
6) Use of atmospheric storage tank under pressure
7) The charging amount exceeds the specified limit.
8) No thermometer is installed in the abnormal temperature storage tank.
9) The container is cracked and still in use.
10) The storage tank is damaged by frequent alternating loads of vacuum and nitrogen.
11) Low boiling point solvent or liquefied gas storage tank is exposed to direct sunlight.
12) Outdoor storage tanks and other vehicles are in danger of collision.
13) The cofferdam hole in the dangerous goods tank farm is not blocked.
14) The protective dike of hazardous chemicals tank farm is not tightly blocked, and rainwater drainage holes are arbitrarily opened.
15) The cut-off valve leading to the drain pipe is in an unsafe state such as normally open.
16) For the outlet pipeline of flammable or corrosive materials in hazardous chemicals tank farm, the bracket is not provided with the compensation measures of hanging pressure spring, or the flexible connecting short pipe is directly adopted.
17) There are no warning signs in the hazardous chemicals tank farm, such as no cell phones, no fire sources, height limit and speed limit.
18) Dangerous goods tank farm has no leakage, feeding operation records and daily inspections.
19) Tractors enter the dangerous goods tank farm at will.
20) There are open flames or forest fires around the dangerous goods tank farm.
21) Electric furnaces, electric teapots and electric heating plates are used illegally in the operation room of dangerous goods tank farm.
22) The tank car has no grounding device at the loading and unloading location.
23) There are no measures to prevent the operator from falling from the tanker.
24) Tanks without effective flame arresters and unqualified vehicles (damaged lighting or brake failure) enter the tank farm.
25) The safety accessories (pressure gauge, thermometer and safety valve) of tank car storage tank have no inspection date or are invalid.
26) The tank of tank car is not marked with the next inspection date of pressure vessel.
27) There is no electrostatic drag chain, anti-virus equipment or valve leakage on the tank.
28) Before and after discharging, the grounding did not stand for more than 10 minutes.
29) When the tanker is discharging, the driver and escort leave the unloading site, and there is no on-site supervisor.
30) Open and splash discharging are adopted.
31) When discharging, make the storage tank exceed the standard liquid level or overflow with full material.
32) The hose or flange leaks when the vinyl chloride tanker is discharging.
33) When vinyl chloride is transported and fed, the tank is full.
34) When the tanker is not fully loaded, it will be transported and discharged in the factory for many times.
35) The unloading vehicle is a flameout and hand brake vehicle or a vehicle that starts during unloading.
36) When high-strength lightning and lightning strike are frequent, engage in unloading operation.
37) There are no two oil tank grounding points.
38) When loading and unloading gasoline and toluene, the operator did not wear antistatic work clothes and shoes.
39) Accident cofferdam and emergency spray dilution facilities are not set in the storage area of liquid ammonia and other storage tanks.
40) No emergency spraying and eye washing facilities are set on site.
41) There are no measures to prevent the wrong loading of materials, such as loading ethyl acetate into gasoline tanks.
42) stand on the petrol tank for welding.
43) Without cleaning, cut the petrol tank or weld the storage tank.
44) Liquid ammonia and vinyl chloride storage tanks are overloaded.
45) When the tanker is discharging, it will block the fire escape and occupy the access road.
46) The receiver leaves the unloading site.
47) Tools easy to generate sparks such as iron and plastic are used at the loading and unloading site.
48) There is no operation record for the material storage tank sent to the workshop by the tank farm.
3. Condenser and reboiler
1) Leakage caused by corrosion and gasket aging.
2) The material temperature after condensation is too high.
3) The heat exchange medium layer is blocked by silt and microorganisms.
4) High temperature surface is unprotected.
5) When cooling high-temperature liquid (such as 150℃), the inlet and outlet valves of cooling water are not opened, or the cooling water volume is insufficient.
6) When the evaporator is used for the first time, the temperature rises rapidly.
7) The shock-proof measures are not taken into account in the heat exchanger, so that the pipeline connected with it is loose and leaked due to vibration.
4, pipes and fittings
1) After the pipeline is installed, the internal welding slag and other foreign bodies are not cleaned.
2) The mirror glass is not clean or damaged.
3) The pressure resistance and temperature resistance of the selected viewing tube material are improper, and the viewing tube is improperly installed.
4) The sight tube is broken or used under pressure for a long time.
5) Anti-static grounding wire damage
6) pipes, flanges or bolts are seriously corroded and cracked.
7) High temperature pipeline is not insulated.
8) the vent tube is made into an elbow.
9) The pipeline material and flow direction are not clearly marked.
10) The color code of the pipeline is unclear.
11) During commissioning, valves connected in series with different materials were not blindly dead.
12) Abandoned pipelines are not cleaned in time.
13) The installation position of the pipe valve is low, which is easy to bump the head or is difficult to operate.
14) No protective measures have been taken for corrosive materials, such as pipelines and flanges, which are easy to leak.
15) There is the possibility that water, nitrogen, air and steam may enter the material pipeline.
16) Iron drums or plastic drums containing inflammable and explosive materials are placed beside high-temperature pipelines.
17) The materials of pipes or pipe fittings are unreasonable and easy to corrode.
18) Glass tube level gauge has no protective measures.
19) No protective metal net is installed at the mirror glass that may explode.
20) check valve can’t flexible action or failure.
21) Power failure of electric valve and gas stop of pneumatic valve.
22) Pressure pipelines such as hydrogen are not regularly maintained or run in spite of illness.
23) When using the pressure pipeline, the operators are untrained or unlicensed.
24) Maintenance personnel are not qualified to repair or transform pressure pipelines.
25) The welding quality of pressure pipeline is poor, and there are welding defects such as undercut, blowhole, slag inclusion and incomplete penetration.
26) The pressure pipeline is not equipped with safety accessories in accordance with regulations or the safety accessories are overdue and not verified.
27) No files and operating procedures have been established for pressure pipelines.
28) Glass lined pipes are impacted by steel pipes.
29) The existing pipeline valve is still used after the production process medium is changed, and the material adaptability is not considered.
30) The nitrogen pipe and the air pipe are connected in series.
31) Salt water pipe and cooling water pipe are connected in series.
5, delivery pump, vacuum pump
1) Pump leakage
2) Abnormal noise
3) The coupling has no protective cover.
4) The pump outlet is not equipped with pressure gauge or check valve.
5) When it is stopped for a long time, the liquid in the pump and pipeline is not drained, causing corrosion or freezing.
6) When the positive displacement pump is running, the outlet valve is closed or the safety backflow valve is not installed.
7) The inlet pipe diameter of the pump is small or the pipeline is long or there are many turns.
8) The installation height of centrifugal pump is higher than the suction height.
9) No antistatic belt is used.
6. Centrifuge
1) the solvent is filtered, and the nitrogen is not filled or the nitrogen pipeline is blocked or there is no flowmeter to display on site.
2) When the solvent needs to be filtered by centrifuge in the fine drying package, the oxygen detector and alarm device are not installed.
3) Brake quickly or with auxiliary tools (such as iron bars).
4) Centrifuge is not effectively grounded.
5) Anti-static belt is not used in the explosion-proof area.
6) When the centrifuge is running, the vibration is abnormal.
7, double cone
1) No fence and safety interlock device.
2) personnel climb into the double cone to replace the vacuum bag.
3) The drive belt is unprotected
4) shaft seal leakage
5) The vacuum pipeline is blocked or the vacuum valve is not opened when in use.
8. Gas cylinders
1) The gas cylinder is not equipped with a cap and a shockproof ring.
2) When hydrogen cylinders are transported and stored in summer, there is no shading measure, which leads to exposure.
3) Some gas cylinders exceed the annual inspection period.
4) When acetylene cylinder and oxygen cylinder are used at the same time, the safety distance is less than five meters.
5) Close the hydrogen cylinder valve with gloves with catalyst.
6) Knock the collision cylinder.
7) After the gas cylinder is used, the air pressure is less than 0.05Mpa.
8) Gas cylinder group, pipeline connection and valve damage
9) When the hydrogen bottle is used, the anti-static device is not used or it is broken.
10) There is no anti-falling measure for gas cylinders.
11) There are ditches and back channels in the storage place.
12) The storage place is not ventilated or poorly ventilated or corrosive gas enters.
13) Lack of fire fighting equipment
14) acetylene cylinders are put down for use.
15) The color of the gas cylinder is blurred.
[2] Electrical instruments
1. Non-explosion-proof electrical appliances or control cabinets are set in the explosion-proof area.
2. The window glass of the transformer room is damaged.
3. There are many sundries in the power distribution room.
4. There are steam water, material pipes, dust and corrosive substances in the distribution room, which leads to the aging of electrical equipment in the electrical cabinet and leads to short circuit accidents.
5, transformer outdoor acid fog corrosion or solvent infiltration or dust.
6. There are clothes and other sundries behind the control cabinet or substation cabinet.
7. The power distribution cabinet is too old and prone to short circuit.
8, cable near the high temperature pipeline.
9. Leakage of material pipes and sewage pipes around overhead cables causes corrosive materials to flow into the cable bridge.
10. Buried cables are corroded by groundwater.
11, cable shaft, ditch sewage serious infiltration.
12. The cable tray is seriously corroded.
13, cable protection casing aging fracture.
14. When cables or steel pipes laying electrical lines pass through holes in walls or floors between different places, they are not strictly blocked with non-combustible materials.
15, disorderly pull activity exhaust, lead to cable joint fall off, leakage.
16. The equipment tag number corresponding to the switch button is unclear.
17. There are messy and unknown cables in the workshop.
18, emergency lighting is not installed or broken.
19, open-air motor without protective cover
20, operation site illumination is not enough.
21. The electrical equipment is not matched with the electrical equipment (the calf pulls the cart and the old cow pulls the cart), resulting in heat damage and fire of the electrical equipment.
22, electrical equipment, cable tray flush
23, explosion-proof mirror lamp, lighting wing screw loose, light leakage.
[3] Static electricity
1. In inflammable and explosive places, the reaction kettle, pipeline, storage tank, condenser, delivery pump, flange and valve are not grounded or poorly grounded.
2. In inflammable and explosive places, the powder feeding hopper is not grounded and filled with nitrogen.
3, more than the safe flow rate (v2<0.64/d) to transport gasoline, toluene, cyclohexane and other liquids.
4. The hydrogen flow rate in the main pipe exceeds 12m/s, and the branch pipe exceeds 8m/s.
5. Spray gasoline from a high position into the bottom of the storage tank or the ground.
6. When nitrogen is not filled, aluminum isopropoxide and magnesium powder are put into the reaction kettle containing gasoline and toluene from the open funnel.
7. Wear clothes, shoes, hats and strenuous activities in inflammable and explosive places.
8, in flammable and explosive places, with chemical fiber material mop or rag scrub equipment or the ground.
9. Fill the plastic bucket with gasoline.
10. Wash work clothes or mop the floor or steel platforms and floors with solvents such as gasoline.
11. The wall of stainless steel and carbon steel storage tanks is not grounded with welded steel bars or flat steel, and there are no two grounding points over 50㎡.
12. There are places where flammable and explosive gases are emitted, and measures such as humidification are not adopted to eliminate electrostatic hazards.
13. Absorb or pack toluene or recycle toluene with plastic pipes.
14. Transport or stir gasoline with compressed air.
15. Anti-static slippers are not used in the explosion-proof clean area.
16, grounding flat steel, roof lightning protection belt rust, serious corrosion.
17, higher than the roof of the metal equipment welded steel into the lightning protection zone.
[4] Production site
1, storage of raw materials or waste is more.
2, the scene "run, run, drip, leak".
3. The insulation layer is damaged
4. Lack of effective fence
5. Normally closed fire doors are normally open
6. The operation posts with dust (magnesium powder, zinc powder, etc.) were not cleaned up in time.
7, metal sodium, sodium hydrogen storage, no rainproof measures or waste barrels, waste bags stored at will.
8. The fire escape is blocked or all kinds of pipelines and their supports hinder the passage.
9, lack of fire extinguishers or expired rust or fire belt, fire hydrant does not meet the requirements of fire control.
10. The waste bucket has multiple labels.
11, strong oxidant (hydrogen peroxide, potassium permanganate, etc.) stacked on the wooden frame.
12, steel platform shaking amplitude is too large.
13, steel platform or steel column corrosion is serious.
14. The solvent concentration in some areas exceeds the standard.
15, high valve handle, iron bars, etc. are easy to fall.
16, concrete floor vibration is big.
17, outdoor steel shed or roof sundry.
18, anti-virus equipment expired or invalid.
19. Non-production appliances (food, newspapers and novels) are stored at the production site.
20. Lack of heatstroke prevention and cooling facilities in summer.
21. Outdoor small-diameter water pipes are not insulated in winter.
22. There are no sanitary facilities such as emergency shower and eye washing in the workshop or they are damaged.
23. The vehicle enters the production site without flame arrester.
24. Flammable and explosive places are not equipped with combustible gas alarm or fail.
25, reaction kettle, storage tank, pump, etc. are not marked with the equipment item number and name.
26, iron gate without fixed bolt, once the wind is strong, it may make the iron gate sparks, leading to danger.
27, warehouse threshold is low, in the event of an accident, dangerous goods will overflow.
28. Iron plates and steel pipes are stored on the ground at the production site.
[5] Personnel and site operation
1. There is no post operation record or incomplete operation record.
2. Absorbing, filling and transporting corrosive articles without wearing protective equipment.
3. There are phenomena such as the operators leaving their posts, leaving their posts and sleeping in their posts.
4. Dust masks were not worn at feeding posts such as powder.
5, quick switch valve
6. The layered kettle and tank bottom valve were not closed after layered.
7, layered kettle, tank water valve is too open, resulting in oil in the water discharged into the sewage pool or drainage time is too long to forget to close the valve and run away.
8, high temperature kettle, tower into the air.
9. The extraction catalysts (such as palladium carbon, activated nickel, etc.) are scattered on site.
10. Use iron bars to poke the blocked materials in pipes and kettles or use non-explosion-proof equipment to generate sparks.
11. No ear protectors or earplugs are worn in noisy environment.
12, storage tank overpressure use
13. Where flammable and explosive solvents such as gasoline and toluene are used, nitrogen gas is not used to replace the kettle and tank.
14, smoke, poor ventilation or lack of oxygen
15. Open the lid of the reaction kettle under pressure.
16. Employees have occupational taboos or allergies or have been exposed to poisons for too long.
17, emergency valve or emergency switch is not easy to operate.
18. Wear nail shoes or high heels and sandals in inflammable and explosive places.
[6] Civil engineering
1. There are no preventive measures (such as flame retardant material plugging) for the pipeline wells on the upper and lower floors where the fire may spread.
2. Explosion-proof wall and light roof are not used in the process with explosion danger, or sufficient explosion-proof surface is not considered.
3. The designed number of entrances, exits and emergency passages is insufficient or blocked or without obvious signs.
4. The foundation of the workshop has been corroded by acid and alkali substances, and the columns and beams have been seriously damaged.
5, when there is a strong wind, steel window glass is easy to fall off.
6. The stairs are too narrow or steep.
7. Poor indoor drainage or long-term water and oil accumulation in low-lying areas.
8. There is not enough space between the top of the head and the ceiling in the passage or work place.
9, in the case of unknown underground pipelines (water pipes, cables, etc.), dig the road at will.
10. Use large machinery to dig near underground cables and pipelines.
11. When hot work is carried out in the fire-forbidden area, the production workshop has not sent someone to monitor it.
12. Abnormal conditions (pipeline breakage, leakage, etc.) occurred during the construction, and the work was not stopped immediately for emergency treatment.
13. Excavated ditches, pits, pools, etc. and damaged pipelines are not provided with fences and signs, and lighting is not provided at night.
14, found that the soil may collapse or slide, did not stop working.
15. There are no measures to prevent underground empty tanks and pools from floating up.
16. During the operation of lowering the tank and the pool, the corresponding examination and approval procedures have not been handled or implemented in accordance with the examination and approval requirements (such as the implementation of labor insurance supplies and guardians), and the operation is not in place.
17. During non-civil work, start work without going through the "non-infrastructure employment procedures" or knowing the corresponding possible risks before the work, and with inadequate safety measures.
[7] production maintenance
1, cleaning and maintenance in the container, in case of danger, there is no emergency escape facilities or measures.
2, hot work without guardian or guardian by recent employees or illegal hot work.
3. Overload hoisting
4. Tools or hanging objects are not properly fixed.
5. Not equipped with or wearing protective equipment (safety helmet, safety belt, etc.)
6, no warning signs or signs have been blurred (such as to prevent electric shock, prevent falling objects, etc.)
7. During maintenance, step on suspended pipelines or small-diameter plastic pipelines and glass-lined pipelines or use unsafe climbing facilities.
8, electric welding machine, manual power tools and other cable damage caused by leakage, zero line damage or jumper.
9, blindly into the sewage pool, deep ditch, deep pool operation.
10. In winter, the pipe rack is frozen and slippery, without anti-skid measures.
11. The welder of the installation company has no welding certificate or the repairman has not received relevant training.
12. Work directly on the roof of fragile materials such as asbestos shingles and linoleum.
13, high homework, did not take preventive measures for cross homework.
14. When working at heights, the zero line of the electric welding machine is not connected to the welding position.
15. Do not wear a gas mask when working in areas with peculiar smell or possibly toxic gas.
16. No safety fence or safety net is set when repairing and digging holes in the wall at high places.
17, clean up the dangerous materials scattered from top to bottom.
18, manned with hoisting machinery
19, homework at night without enough lighting.
20, in case of more than six levels of strong winds or other bad weather, is still working high in the open air.
21. When working in the kettle, there are no more than two people outside the kettle for supervision.
22. When the kettle was overhauled, the power supply was not cut off and the sign "Someone overhauled, no closing" was hung.
23. The kettle was not effectively cleaned before entering the tank.
24. Before entering the tank, the concentration of combustible gas, oxygen content and toxic gas (CO, H2S) were not analyzed.
25. Before entering the tank, the material pipelines such as raw materials, solvents, steam, water, nitrogen and other pipelines were not reliably isolated.
26, in the process of maintenance, not to the kettle sampling analysis on a regular basis.
27. The sign "There is someone in the tank" is not hung on the obvious position outside the kettle.
28. The "double inspection system" was not implemented during the tank feeding operation.
29. The lighting in the kettle does not meet the safe voltage standard, and the voltage is greater than 24V in dry condition and 12V in wet condition.
30, after maintenance, not check, clean up the clutter is turned on.
31. Working in the kettle for a long time without rotation.
32, maintenance, kettle lack of necessary ventilation facilities.
33. Weld the outer wall surface or inner wall of the glass-lined tank.
34, into the glass-lined kettle, the tank is not paved with cushions.
35, rapid heating or rapid cooling glass-lined kettle
36. When the glass-lined tank is used, the bolts and clips of the tank mouth or manhole fall into the kettle.
37. When glass-lined kettle, stainless steel kettle and carbon steel kettle are used, acid enters the kettle jacket.
38. The selected materials have not been audited for temperature, PH and corrosion solubility, and the occasions where there may be pressure have not been specially audited for pressure.
39. After maintenance, all the spaces in the kettle and the maintenance site have not been completely cleared and rechecked, and the trial operation has started.
40. After the overhaul, the relevant matters have not been fully communicated, the changes have not been confirmed and approved, and the relevant personnel have not been fully trained and understood.
41, maintenance without operation confirmation that feeding production.
[8] Production technology
1, there is a sudden reaction, lack of response measures and training.
2. Change the feeding amount or ratio at will.
3, improve the process or new technology, no safety assessment.
4. The process change has not been strictly reviewed and approved.
5. The process is operated within the explosion limit of combustible gas.
6. When using highly toxic materials, adopt exposure operation.
7, did not write the process operation procedures for trial production.
8. The physical properties of the materials used and the precautions for safe use have not been compiled.
9. When the materials used are decomposed, the heat generated is not accounted for in detail.
10. There is potential danger of dust explosion.
11. When some raw materials cannot be put into use in time, there is danger when the materials in the kettle are temporarily stored.
12, raw materials or intermediates in storage will occur spontaneous combustion or polymerization or decomposition risk.
13. Various parameters (temperature, pressure, etc.) in the process are close to the dangerous limit.
14. When an abnormal situation occurs, there is no measure to discharge the reactants quickly.
15. There are no measures to prevent and stop the sharp reaction.
Source: Kunshan Safety Supervision, Minhang Safety Production